Method for manufacturing wire harness with branch connection terminals

• US 20010009067A1
• Filed: 01/05/2001
• Published: 07/26/2001
• Est. Priority Date: 01/26/2000
• Status: Active Grant

• Current Assignee: Yazaki Corporation
• Original Assignee: Yazaki Corporation
• Inventors: Nagai, Kentaro
• Granted Patent: US 6,532,652 B2
• Time in Patent Office: Days
• US Class Current: 29/866
• CPC Class Codes: H01R 12/68 comprising deformable portions
• CPC Class Codes: H01R 43/01 for connecting unstripped conductors to contact members having insulation cutting edges
• CPC Class Codes: H05K 1/118 specially for flexible printed circuits, e.g. using folded portions
• CPC Class Codes: H05K 3/326 the printed circuit having integral resilient or deformable parts, e.g. tabs or parts of flexible circuits H05K3/365 takes precedence
• CPC Class Codes: Y10T 29/49128 Assembling formed circuit to base
• CPC Class Codes: Y10T 29/49156 with selective destruction of conductive paths
• CPC Class Codes: Y10T 29/49188 with penetrating portion
• CPC Class Codes: Y10T 29/4919 Through insulation

Abstract

In a method for fabricating a wire harness with branch terminals, a flexible flat cable (FFC) (11) is first prepared by arranging multiple conductive strips (12) in parallel to each other at a predetermined interval, and by laminating a pair of base films (13) with the conductive strips between them. Then, a row of slots (14A) are formed between any two adjacent conductive strips at a predetermined distance from an end of the FFC, thereby defining a connection area (A) between the end of the FFC and the row of slots. Then, multiple connection terminals (16), each having a contact (17) and a plurality of projections (19), are fixed to the connection area of the FFC by causing the projections of each connection terminal to pierce through one of the conductive strips. Finally, slits (14B) are formed from the end of the FFC so that the slits extend between any two adjacent conductive strips and communicate with the associated slots.

Claims

1. A method for fabricating a wire harness with branch terminals, comprising the steps of:

preparing a flexible circuit belt that has two or more conductive strips arranged in parallel to each other at a predetermined interval and sandwiched by a pair of base films;

fixing connection terminals, each having a contact and a plurality of projections, to an end portion of the flexible circuit belt by causing the projections of each connection terminal to pierce through one of the conductive strips; and

after fixing the connection terminals, forming one or more slits between any two adjacent conductive strips, each slit extending from an edge of the end portion at a predetermined length, thereby branching out the flexible circuit belt.

2. The method of

claim 1

, wherein the step of preparing a flexible circuit belt includes laminating the base films with the conductive strips between them.

3. The method of

claim 1

, wherein the step of preparing a flexible circuit belt includes forming conductive strips by etching or plating on a first base film, and forming a second base film over the conductive strips and the first base film.

4. The method of

claim 1

, further comprising the step of inserting the connection terminals fixed to the associated branches of the flexible circuit belt into a connector housing.

5. A method for fabricating a wire harness with branch terminals, comprising the steps of:

preparing a flexible circuit belt that has two or more conductive strips arranged in parallel to each other at a predetermined interval and a pair of base films sandwiching the conductive strips;

forming a row of slots between any two adjacent conductive strips at a predetermined distance from an end of the flexible circuit belt, thereby defining a connection area between the end of the flexible circuit belt and the row of slots;

fixing connection terminals, each having a contact and a plurality of projections, to the connection area of the flexible circuit belt by causing the projections of each connection terminal to pierce through one of the conductive strips; and

after fixing the connection terminals, forming one or more slits between any two adjacent conductive strips so that the slits extend from the end of the flexible circuit belt and communicate with the associated slots.

6. The method of

claim 5

, wherein the step of preparing a flexible circuit belt includes laminating the base films with the conductive strips between them.

7. The method of

claim 5

, wherein the step of preparing a flexible circuit belt includes forming conductive strips on a first base film by etching or plating, and forming a second base film ver the conductive strips and the first base film.

8. The method of

claim 5

, further comprising the step of inserting the connection terminals fixed to the associated branches of the flexible circuit belt into a connector housing.

9. A method for fabricating a wire harness with branch terminals, comprising the steps of:

preparing a flexible circuit belt that has two or more conductive strips arranged in parallel to each other at a predetermined interval and a pair of base films sandwiching the conductive strips, any two adjacent conductive strips defining a non-conductive region between them;

forming two rows of slots in the middle of the flexible circuit belt in such a manner that two slots are aligned along the longitudinal axis of each non-conductive region of the flexible circuit belt at a predetermined distance between them, the two rows of slots being symmetrical with respect to a centerline extending in the width direction of the flexible circuit belt between the rows;

folding the flexible circuit belt in double along the centerline between the two rows of slots so that a row of slots lies on top of the other row of slots;

fixing connection terminals, each having a contact and a plurality of projections, to the folded portion of the flexible circuit belt by causing the projections of each connection terminal to pierce through one of the doubled conductive strips of the folded flexible circuit belt; and

after fixing the connection terminals, forming one or more slits between any two adjacent conductive strips, the slits extending from the folded edge of the flexible circuit belt and communicating with the overlaid slots.

10. The method of

claim 9

, wherein the step of preparing a flexible circuit belt includes laminating the base films with the conductive strips between them.

11. The method of

claim 9

, wherein the step of preparing a flexible circuit belt includes forming conductive strips on a first base film by etching or plating, and forming a second base film over the conductive strips and the firsi base film.

12. The method of

claim 9

, further comprising the step of inserting the connection terminals fixed to the associated branches of the flexible circuit belt into a connector housing.